Trianco 224378 HE User manual

Brand: Trianco

Model: 224378 HE

Type: User manual

Balanced Flue Kit Range

FOR EUROSTAR PREMIER & CONTRACTOR HE

CONDENSING OIL-FIRED CENTRAL HEATING BOILERS

INSTALLATION INSTRUCTIONS

To be retained by the householder

Please read these instructions carefully before installation

and use of the appliance.

HEALTH AND SAFETY INFORMATION

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEERS

Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a

requirement to provide information on substances hazardous to health (COSHH Regulations 1998).

Trianco takes every reasonable care to ensure that these products are designed and constructed

to meet these general safety requirements, provided they are properly installed and used.

To fulfil this requirement, products are comprehensively tested and examined before despatch.

When working on the appliance, it is the responsibility of the user/engineer to ensure that any

necessary personal protective clothing or equipment is worn appropriate to parts which could be

considered hazardous or harmful.

This appliance may contain some of the items below:

Insulation and Seals

Glass rope, mineral wool, insulation pads, ceramic fibre, glass insulation.

May be harmful if inhaled. May be irritating to the skin, eyes, nose and throat. When handling,

avoid inhalation and contact with the eyes. Use disposable gloves, face masks and eye protection.

After handling, wash hands and other exposed parts. When disposing, reduce dust with water

spray and ensure all parts are securely wrapped.

Glues, Sealants and Paints

hammer

Glues, sealants and paints are used in this appliance and present no known hazards when used in

the manner for which they are intended.

Kerosene & Gas Oil Fuels (Mineral Oils)

Avoid as far as is possible any skin contact with mineral oils or with materials contaminated with

mineral oils. The effects of mineral oils on the skin may vary according to exposure:

1) May remove the protective grease normally present on the surface of the skin, rendering it dry,

liable to crack and more prone to damage caused by cuts and abrasions.

2) May result in skin rashes. Seek immediate medical attention for any rash, wart or sore

developing on any part of the body, especially the scrotum.

Never breathe any mineral oil vapours. Do not fire the burner in the open (i.e. not properly situated

in the boiler) as misfiring may result in unburned oil vapours.

When handling mineral oils, a suitable barrier cream containing lanolin is highly recommended,

along with a strict routine of personal cleaning.

Under no circumstances should mineral oils be taken internally.

CONTENTS

BALANCED FLUE INSTALLATION NOTES

TERMINAL CLEARANCES

HORIZONTAL BALANCED FLUE KITS

HIGH LEVEL BALANCED FLUE ADAPTOR KITS

VERTICAL BALANCED FLUE KITS

OPTIONAL EXTRAS (EXTENDING THE FLUE)

Page No.

5-6

7-10

11-13

BALANCED FLUE SYSTEMS

The Trianco balanced flue system offers much greater

flexibility for siting the boiler compared with a conventional

chimney. The only requirement is for a suitable outside

surface, through which to fit the terminal.

In addition to the siting benefit, the performance of balanced

flue boilers is virtually unaffected by high wind conditions as

the wind pressures are applied equally to both the air intake

and discharge points, thus creating a balanced condition.

Whereas some balanced flue boilers rely on case sealing to

achieve a room seal, Trianco boilers have a sealed air duct

system which maintains room sealed performance even

when the casing is removed for burner commissioning and

service.

The use of the balanced flue principle also enhances the

overall thermal efficiency of the boiler, as the incoming air

extracts waste heat from the flue and returns it as pre-

heated air to the burner to aid combustion.

Balanced-flue condensing boilers are designed to operate at

low noise levels.

INSTALLATION NOTES

1. At certain times during operation, a plume of

condensation will be produced from the terminal. When

positioning, this should be taken into consideration to

ensure a nuisance is not caused to neighbouring

properties.

2. The flue terminal should not be positioned where the

products of combustion could enter the building (refer to

fig 1 for guidance).

3. Keep the terminal clear of infra-red sensing devices

such as those used to control security lighting.

4. Positioning of the terminal below a balcony or carport

should be avoided.

5. As the system operates under positive pressure, it is

essential that all flue joints are sealed correctly.

6. Only 28. second kerosene class C2 to BS 2869 has

been tested for use with this appliance.

Note: Trianco balanced flue kits have been designed and

tested exclusively for use with Trianco boilers. As

such, compatibility with other makes of boiler

cannot be guaranteed.

FIG 1 – TERMINAL POSITIONS

Horizontal Balanced Flue Kits (2334 & 2335)

Before commencing assembly, please make sure that you have correctly identified the placement of each pipe section and

that all ‘O’ ring seals are in position and well-lubricated.

Assembly Method (figs 2 to 3)

1. Having decided the position of the boiler, accurately mark

out the position of the terminal and cut a circular hole

130mm in diameter through the wall.

2. Remove the four nuts on top of the boiler and remove the

flue socket, leaving the gasket (item 5, fig 2) in position.

3. Fit the sealing plate (4) over the four studs, and place the

terminal gasket (3) onto the sealing plate. Position the

boiler.

4. Assemble the flue by sliding the terminal section (2) into

the elbow section (1), making sure all ‘O’-ring seals (6) are

in position. Slide the completed assembly through the wall

from the inside.

5. Slide the flue mounting plate on the elbow section over the

four studs on top of the boiler and secure in position using

the nuts previously removed.

6. Adjust the terminal length as required, making sure a

minimum distance of 140mm is kept from the end of the

terminal from the external face of the wall.

7. Connect the hose from the burner to the socket on the end

of the terminal using the jubilee clip provided.

8. Seal around terminal on the inside and outside wall with

an appropriate material.

Important Notes:

(a) To aid assembly, it may be necessary to apply a thin bead

of lubricant to all flue joints which incorporate ‘O’-ring

seals.

(b) As the flue system operates under positive pressure, all

flue joints must be well sealed. All joints which do not

incorporate ‘O’-ring seals should be sealed with silicone

sealant.

it is important that all seals are made and the correct

gaskets used.

(d) To ensure that any condensate produced in the flue drains

away correctly, incline the flue slightly upwards from the

boiler.

TERMINAL GUARD

Where the terminal is positioned in a place where there is the

possibility of contact being made by persons, of damage to the

terminal, or if it is lower than 2 metres from ground level, an

approved terminal guard is necessary.

Generally, exhaust 2 metres above ground level will alleviate

the requirement for a terminal guard.

A suitable stainless steel terminal guard is available from

Trianco (part code 223920).

FIG 2

2334 & 2335 HORIZONTAL BALANCED

FLUE KITS

FIG 3

2334 & 2335 HORIZONTAL BALANCED FLUE KIT DETAILS

FIG 4 - 2355 & 2356 Horizontal Balanced Flue

(to be used in conjunction with 2357 High Level Adaptor Kit only)

FIG 5

2357 – High Level Adaptor Kit

(used in conjunction with 2355 or 2356

Horizontal Balanced Flue Kits only)

FIG 6

2357 – HIGH LEVEL ADAPTOR KIT

(USED IN CONJUNCTION WITH 2355 AND 2356 HORIZONTAL FLUE KITS ONLY)

Please note, the flue lengths given on this

page are for the standard kits only; see page

14 for details of optional extension pieces. In

addition, the total flue length (horizontal &

vertical) must not exceed 6000mm (50/90) or

4240mm (100/125 & Combi 110).

High-Level Balanced Flue Kit (2357)

Before commencing assembly, please make sure that you have correctly identified the placement of each pipe section and

that all ‘O’ ring seals are in position and well-lubricated. Any white pipe exposed to the elements should be protected with a

suitable material. Place all weld seams to the rear.

ASSEMBLY METHOD

Before assembly, determine the length of flue required and if

necessary discard the mid-section. See "alternative vertical

lengths" (adjacent) for details of different flue lengths.

1. Having decided the position of the boiler, cut a hole

130mm diameter in the wall. Refer to fig 6 and "alternative

flue heights" for high level flue positions.

2. Remove the boiler top casing and the conventional-flue

socket. Ensure the flue gasket remains in position.

3. Refer to fig 5; place items 8, 7, 6 & 5 in order onto the top

of the boiler. Secure with the nuts provided. Ensure all 'O'-

ring seals (item 9) are in position on all sections of pipe.

Apply a bead of lubricant around each 'O'-ring.

4. Fit the lower flue section (item 4) to the spigot (item 6),

now situated on top of the boiler, ensuring the 'O'-ring

creates a good seal. Ensure the hose connection on the

white outer pipe is directed to the front of the boiler.

5. Fit the flue mid-section (item 3) to the lower flue section in

the same manner, pushing firmly down until the outer

sections meet. Use the clamping strap (item 2) to fasten

these items securely together.

6. Ensuring that all 'O'-ring seals are in position and well-

lubricated, fit the elbow (item 1, fig 4) from the horizontal

balanced flue kit to the top of the flue mid-section, pushing

firmly together until the outer sections meet. Use the

clamping strap to fasten these items securely together.

7. Decide the length of horizontal run required and slide the

terminal (item 4, fig 4) into the horizontal mid-section

(item 2, fig 4). Once in the required position (and ensuring

that at least 140mm will project from the outside wall), seal

these items together using a suitable material.

8. Ensuring that all 'O'-rings are in position, slide the

completed terminal assembly through the wall and fit to

the flue elbow, pushing firmly together until the outer

sections meet. Use the remaining clamping strap to fasten

these items securely together.

9. Use the clip provided to secure the air hose from the

burner to the connection on the lower flue section.

10. Cut the tabs from the hole in the boiler top casing and fit

the casing into position. Perform a final check of the flue.

Ensure all clamping straps are located over all relevant

flue joints.

11. Seal any remaining gaps in the wall around the horizontal

flue section with a suitable material.

ALTERNATIVE FLUE HEIGHTS

Should the height of the flue (see fig 6) not meet your

requirements, alternative arrangements can be made. The

vertical mid-section (item 3, fig 5) can be discarded to

subtract 760mm from the total height. The horizontal section

should instead be fitted to the short vertical section, using

the clamping strap provided.

Alternatively, purchase additional sections of flue pipe to

extend the vertical distance. See page 14 for details.

ALTERNATIVE HORIZONTAL LENGTHS

Should the horizontal length of the standard flues not meet

your requirements, an additional section of flue pipe can be

purchased to extend the maximum wall thickness limit. See

page 14 for details.

ADDITIONAL ELBOWS

When used in conjunction with additional horizontal lengths

of flue, 45º and 90º elbows can be purchased in order to

offset the flue on the horizontal plane. See page 14 for

details.

Additional 45º elbows can be purchased to offset the vertical

sections of flue. 90º elbows cannot be used on the vertical

sections. See page 14 for details.

IMPORTANT: When used on boilers of outputs 90,000

Btu/h or less, the total flue distance, vertical and horizontal,

must not exceed 6000mm. Flues used on boilers of outputs

above 90,000 Btu/h must not exceed 4240mm. Any 45º

elbows used in the assembly contribute 500mm to the

calculation. 90º elbows contribute 1000mm to the

calculation.

To ensure that any condensate produced in the flue drains

away correctly, incline the flue slightly upwards from the

boiler.

TERMINAL GUARD

Where the terminal is positioned in a place where there is

the possibility of contact being made by persons, of damage

to the terminal, or if it is lower than 2 metres from ground

level, an approved terminal guard is necessary.

Generally, exhaust 2 metres above ground level will

alleviate the requirement for a terminal guard.

A suitable stainless steel terminal guard is available from

Trianco (part code 223920).

Vertical Balanced Flue Kit (2360)

Before commencing assembly, please make sure that you have correctly identified the placement of each pipe section and

that all ‘O’ ring seals are in position and well-lubricated. Any white pipe exposed to the elements should be protected with

a suitable material. Place all weld seams to the rear.

ASSEMBLY METHOD

The flue can either be assembled on the ground before attaching to

the boiler, or piece-by-piece in situ. If the former, ensure that all

clamping straps (items 11 & 12, fig 7) are loosely in position over

the flue joints. If the latter, ensure that none of the flue joints are

situated within the joist space.

The total flue length required should be determined before

assembly. If necessary, discard the mid-sections (item 7), as their

use is not essential. See fig 8 for details of different flue lengths.

1. Secure the boiler in position and cut a hole 175mm diameter in

the ceiling and roof. Ensure the flue will have a minimum

clearance of 25mm from any combustible material.

2. Remove the boiler top casing and the conventional-flue socket.

Ensure the flue gasket remains in position.

3. Refer to fig 7; place items 1, 2, 3 & 4 in order onto the top of

the boiler. Secure with the nuts provided. Ensure all 'O'-ring

seals (item 5) are in position on all sections of pipe. Apply a

thin bead of lubricant around each 'O'-ring.

4. Fit the lower flue section (item 6) to the spigot (item 3) which

should now be situated on top of the boiler, ensuring the 'O'-

ring creates a good seal. Ensure the hose connection on the

lower flue section is directed to the front of the boiler.

5. Fit the first flue mid-section (item 7) to the lower flue section,

pushing firmly down until the outer sections meet. Use the

clamping strap (item 11) to fasten these items securely

together. Fit the second flue mid-section (also item 7), and the

third flue section (item 8) to the previous sections in the same

manner.

Note: both instances of item 7 can be discarded if they are not

required. Of the main flue sections, only the use of items 6 & 8

is mandatory. Fit these together in the manner described above.

6. Ensuring that all 'O'-ring seals are in position and well-

lubricated, fit the remaining flue mid-section to the assembly in

the same manner, pushing firmly down until the outer sections

meet. Use the clamping strap to fasten these securely

together.

7. The first terminal section (item 9) fits over the preceding

section of flue without the use of the clamping strap, and in

order to achieve a more accurate fit distance is telescopic

in nature. Once the length has been set, drill through the

outer pipe and secure with self-tapping screws.

8. If necessary, fit the terminal (item 10) to the terminal lower

section before it is attached to the last main flue section.

Push firmly down until the outer sections meet and use the

stainless steel clamping strap (item 12) to fasten these

securely together.

9. Fit the ceiling plates (item 13) centrally over the inner hole,

ensuring the outer flue pipe has a minimum clearance of

25mm from any combustible material. Pack the space with

glass fibre insulation.

10. Secure the flue to the roof space and fit waterproof flashing

(not supplied) around the flue at the roof line.

11. Use the clip provided to secure the air hose on the burner

to the connection on the lower flue section.

12. Replace the top casing.

ADDITIONAL FLUE HEIGHTS & ELBOWS

Should the maximum height of the flue not meet your

requirements, additional sections of flue pipe can be

purchased to extend the vertical distance. See page 14 for

details.

45º elbows can be purchased to offset the flue to keep clear of

any permanent obstructions. See page 14 for details. 90º

elbows cannot be used with this flue.

IMPORTANT: When used on boilers of outputs 90,000 Btu/h

or less, the total flue distance, vertical and horizontal, must

not exceed 6000mm. Flues used on boilers of outputs above

90,000 Btu/h must not exceed 4240mm. Any 45º elbows used

in the assembly contribute 500mm to the calculation.

FIG 7

VERTICAL BALANCED FLUE KIT (2360)

FIG 8

VERTICAL BALANCED FLUE KIT (2360)

Note 'X' – Shorter flue distances can be achieved by

discarding these sections. Longer flue distances can

be achieved by purchasing additional sections of

pipe (see page 14).

Permanent obstructions may be avoided by the use

of 45º elbows (see page 14).

Optional Extras

Combinations of the following items can be purchased in order to provide alternative flue configurations:

2361 – Long Flue Extension 2363 – 45º Elbow

2362 – Short Flue Extension 2364 – 90º Elbow

These items are only to be used in conjunction with high level adaptor kit (2357), or with vertical flue kit (2360).

2362 – Long Flue Extension

2361 – Short Flue Extension

2363 – 45º Elbow

2364 – 90º Elbow

These flue extensions can be used to extend the vertical length

of the flue, or the horizontal length (high level adaptor kit only), in

almost any combination of configurations.

When used on boilers of outputs 90,000 Btu/h or less, the total

flue distance, vertical and horizontal, must not exceed 6000mm.

Flues used on boilers of outputs above 90,000 Btu/h must not

exceed 4240mm.

Any 45º elbows used in the assembly contribute 500mm to the

above calculation. 45º elbows can be used to offset the vertical

sections of flue on both the high level and vertical flue kits.

Ensuring all 'O'-ring seals are in position and well-lubricated,

push the elbow and flue pipe firmly together, fixing together with

the clamping strap provided.

Any 90º elbows used in the assembly contribute 1000mm to the

above calculation. 90º elbows can only be used on the high

level adaptor kits to offset the flue on the horizontal plane.

Ensuring all 'O'-ring seals are in position and well-lubricated,

push the elbow and flue pipe firmly together, fixing together with

the clamping strap provided.

Example:

2 x 45º elbows used to offset

vertical flue extensions.

Note: only 45º elbows can be

used on vertical sections of

flue. 90º elbows must only be

used to offset the flue on the

horizontal plane.

September 2007

Item No. 224378 Issue No. 2

Heating Products and neither the brochure or any part thereof may be reproduced without prior written consent.

TRIANCO HEATING PRODUCTS LTD

Thorncliffe, Chapeltown

Sheffield S35 2PH

Tel: (0114) 257 2300

Fax: (0114) 257 1419

www.trianco.co.uk

Trianco 224378 HE User manual

Brand: Trianco

Model: 224378 HE

Type: User manual

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Trianco 224378 HE User manual

Trianco 224378 HE User manual

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